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Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755553
January 07th 2020 4:19 am
January 07th 2020 4:19 am
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Dw89xj Offline OP
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My buddy said it looks worse than it is but won't be too bad to fix as long as it doesn't keep raining every time he has off work. I'm keeping my fingers crossed that's the last of nasty stuff, but I'm not holding my breath. This is going to turn into a money pit very fast. Maybe I should just scrap it and try to get financed for a new transit, but then I'm paying for the next 5 years or more, I'm not sure il rack up enough miles to make the payments worth it. But Ive never owned a brand new vehicle so it would be nice. I guess il just keep throwing money at this til it's done, I have a soft spot for econolines


98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755787
January 14th 2020 4:39 am
January 14th 2020 4:39 am
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Pennsylvania
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Dw89xj Offline OP
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Well since I'm so far behind where I wanted to be and gave so much to do, I've decided I'm just going to buy the ujoint off-road front bracket kit. He's put alot of work into designing his kit and takes all the headaches out of it.

The driver side is done now for rust repairs from what I'm told and my passenger side should be done this weekend. I will be so glad to get my van back I can hardly contain myself. I have alot of things that I want to do that don't involve it being 4wd for now too. Like installing rear hitch and wiring, hand controls, design and build a power swivel driver seat, suicide knob, interior lighting and make it a little fancy with some crushed velvet and wood, stereo and speakers and backup camera, solar and battery bank, window tint, tow mirrors, vent visors, have ac repaired, ad auxiliary trans cooler, led headlights, taillights, and convert the corner lights to led, clear corner lamps, billet grill, monstaliner the entire exterior, build a bed for in the back and under bed storage, wireless actuators for side doors, CB radio, custom bumpers, and led off road lights floods and spots, awning for the passenger side, and the list goes on. The first three things are priority though.
Luckily almost everything including the 4wd conversion can for the most part be done on the fly without any major downtime.
Alot of people dog on the v6, but looking at the power numbers they're kind of on par with early to mid 90s v8s, I've owned plenty of them in Chevy and Ford and they all did anything I asked of them, hauled towed and played around doing things they weren't really made to do. All I know is it's 100% better than my dodge and just as good as the Chevy I sold, in hind sight I should've sold the dodge.
I just can't wait to get my van back. My wife isn't as enthusiastic, for some reason she doesn't understand upgrading and modifying.


98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755802
January 14th 2020 1:15 pm
January 14th 2020 1:15 pm
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Please if possible, post a picture of the floor pan welding repair? Did your driver floor pan body mount bolt have to be removed? I have a similar issue in my 2008 it looked fine until I pulled the carpet up. Door sill is fine, thank goodness but still need a Flintstones board to get around town. The body mount bolt is rust fused, I hope the 24 inch breaker bar will get it out for a new bolt, before the new metal goes in. Curious if you encountered the same issue, with the body mount?

Attached Files IMG_0159[1].jpgIMG_0161[1].jpg

2001 Dodge 2500 Cargo Van 5.9L V8 HOA Violator
2008 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 6.5 KW Onan
Re: 2002 Econoline 4x4 conversion [Re: Phone_Trucker] #755839
January 15th 2020 2:18 am
January 15th 2020 2:18 am
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Dw89xj Offline OP
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From what he told it was just the floor metal and the step he said the mount and everything around it was still good looking. He also said the floor in back and passenger side is fine just the driver foot area as far as floor rust goes. Just certain areas are terrible I don't know if maybe bad metal, or lack of care/ maintenance. It was a medical transport van I'm not sure why a fleet vehicle would have gotten so bad and never had attention. Oh well my problem now.
It did have aluminum running boards full length so maybe the different metals caused rapid oxidation, I don't know, I'm just hoping it's done soon and gives me another 100,000 miles or at least a good ten years since I average maybe 6000 miles a year if that. My last inspection was emission exempt for being under 5k mi.


98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Phone_Trucker] #755840
January 15th 2020 2:20 am
January 15th 2020 2:20 am
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Originally Posted by Phone_Trucker
Please if possible, post a picture of the floor pan welding repair? Did your driver floor pan body mount bolt have to be removed? I have a similar issue in my 2008 it looked fine until I pulled the carpet up. Door sill is fine, thank goodness but still need a Flintstones board to get around town. The body mount bolt is rust fused, I hope the 24 inch breaker bar will get it out for a new bolt, before the new metal goes in. Curious if you encountered the same issue, with the body mount?


Mine was pretty much like that except the metal behind that black plastic was trash also. I will try to get more pictures he tried to send some but they didn't send for some reason. Yours actually looks nicer than mine if you check page 3 on this thread. I will try and get him to try to send the pictures again

Last edited by Dw89xj; January 15th 2020 2:23 am.

98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755868
January 15th 2020 2:29 pm
January 15th 2020 2:29 pm
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Thanks very much for the info,. I did not want to weld new sheet metal on top of the body mount bolt head in case I ever wanted to change out the body mount bushings (which on mine, are still in pretty good shape), although that would be a much quicker solution to just tack it down over the fused bolt and be done with it. Amazon is delivering a 24 inch breaker bar today for the lower retainer nut which has been soaking in WD-40 for about a week. I have a new bolt and lower retainer nut to put in there, if I can get the old one out.


2001 Dodge 2500 Cargo Van 5.9L V8 HOA Violator
2008 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 6.5 KW Onan
Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755870
January 15th 2020 3:29 pm
January 15th 2020 3:29 pm
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Posts: 14,933
Van Diego California
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If there is that much rust to the point of metal missing …. what does the rest of the under side look like.

Do you really want to make your 4x4 on a rusted chassis. 4x really takes the metal to the limit and to have it rusty to start with is not the best idea, cause when your out there . . There is no shop to make another part & no welder to fix it. just my opinion.

Can you keep the cab & find a better undercarriage, do a ft & rear swap, heck you might find a 4x in terrible shape body wise but undercarriage is in fine shape. Might get that on for a song N dance.

You wouldn't build your house on sand … you'd build your house on rock.


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Re: 2002 Econoline 4x4 conversion [Re: frscke1] #755882
January 15th 2020 7:36 pm
January 15th 2020 7:36 pm
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Posts: 146
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Dw89xj Offline OP
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Originally Posted by frscke1
If there is that much rust to the point of metal missing …. what does the rest of the under side look like.

Do you really want to make your 4x4 on a rusted chassis. 4x really takes the metal to the limit and to have it rusty to start with is not the best idea, cause when your out there . . There is no shop to make another part & no welder to fix it. just my opinion.

Can you keep the cab & find a better undercarriage, do a ft & rear swap, heck you might find a 4x in terrible shape body wise but undercarriage is in fine shape. Might get that on for a song N dance.

You wouldn't build your house on sand … you'd build your house on rock.


That's the weird part, everything else is pretty clean, just that driver side and rockers and quarters. I really don't get it. It's going for safety inspection and emissions before anything else, I'm going to have them look the chassis over really well as they already know my plans for 4x4. I'm thinking/hoping this is one of those you mentioned with a bad body and alright chassis. I keep asking my body guy about the frame and underside of the floors and anything he can check out before I push on. Worst case I will still go 4x4 and just use it for a mud truck and find a better driver, the down side is equipped wheelchair vans are far and few and salty. Getting financed for a transit or sprinter is still rattling around the back of my mind, but then I'm paying for the next 5-8 years.


98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Phone_Trucker] #755883
January 15th 2020 7:39 pm
January 15th 2020 7:39 pm
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Posts: 146
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Dw89xj Offline OP
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Originally Posted by Phone_Trucker
Thanks very much for the info,. I did not want to weld new sheet metal on top of the body mount bolt head in case I ever wanted to change out the body mount bushings (which on mine, are still in pretty good shape), although that would be a much quicker solution to just tack it down over the fused bolt and be done with it. Amazon is delivering a 24 inch breaker bar today for the lower retainer nut which has been soaking in WD-40 for about a week. I have a new bolt and lower retainer nut to put in there, if I can get the old one out.


You can buy body plugs on eBay, I would cut out for the bolt and pop one of those in the hole. I don't think it would be too noticeable if it's just the size of the socket or a hair bigger. Especially if you put carpet and pad over it. I have a 6x6 amphibious atv and it takes 7/8 or 3/4" plugs I bought a big bag of them on eBay, they had a bunch of different sizes.

Last edited by Dw89xj; January 15th 2020 7:41 pm.

98 Dodge shorty hitop mark iv
95 Chevy van 20 regency hitop conversion van
Re: 2002 Econoline 4x4 conversion [Re: Dw89xj] #755897
January 16th 2020 4:39 pm
January 16th 2020 4:39 pm
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Posts: 22
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Exactly the same on my 2008 Econoline, the worst of the rust is by far under the driver's feet and to a lesser degree, under the passenger feet right around the body mount bolt. I have a theory that mine rusted out from underneath around the body mount bolt where water and road salt got between that heavier-gauge curved plate and the floor pan sheet metal around where it was tack welded. I don't know if the factory even used any seam sealer right there. After I get mine fixed I'm going to seal that area up real good!

Added pic of passenger side, there is no hole yet but see the missing metal where the white patch is in the upper left-hand corner. It looks like salt from underneath the floor pan ate it from below and I bet this is how the other side looked too when it first started to corrode. I'm going to cut a smaller patch for the passenger side too and replace the sheet metal here, while the cab is stripped. I bet there is some crusty stuff under there to clean out,

Attached Files IMG_01714.jpg
Last edited by Phone_Trucker; January 16th 2020 5:43 pm. Reason: add passenger side picture

2001 Dodge 2500 Cargo Van 5.9L V8 HOA Violator
2008 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 7 KW Onan
2010 Ford Econoline Ex-Bell Telephone Generator Van, 6.5 KW Onan
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